R59115900 00 Service

Service manual
OL Series
R59115900
R59115900, Current Version
Title: SERVICE MANUAL OL SERIES – Service Manual
ID-no.: R59115900
Revision: 00
Date: October-2010
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Barco – OL Series – R59115900 – service manual – Revision 00 – October-2010 ii
Trademarks
Brand and product names mentioned in this manual may be trademarks, registered trademarks or copyrights of
their respective holders. All brand and product names mentioned in this manual serve as comments or examples
and are not to be understood as advertising for the products or their manufacturers.
Copyright © 2010by Barco

Die Weitergabe sowie die Vervielfältigung aller Unterlagen, die von uns überlassen werden, deren Verwertung
und Mitteilung ihres Inhaltes an Dritte ist nicht gestattet, soweit dies nicht ausdrücklich zugestanden ist. Urheber-
rechte, insbesondere auch solche an Software, werden nur insoweit übertragen, als es für die Erreichung des
speziellen Vertragszwecks erforderlich ist. Zuwiderhandlungen können zu Schadensersatz verpflichten. Alle Rech-
te aus der Erteilung eines Patents oder der Eintragung eines Gebrauchsmusters verbleiben bei uns.
Copyright © 2010 by Barco

All rights reserved. No part of this document may be copied, reproduced or translated. It shall not otherwise be
recorded, transmitted or stored in a retrieval system without the prior written consent of BARCO.
Guarantee and Compensation

Barco provides a guarantee relating to perfect manufacturing as part of the legally stipulated terms of guarantee.
On receipt, the purchaser must immediately inspect all delivered goods for damage incurred during transport, as
well as for material and manufacturing faults. BARCO must be informed immediately in writing of any com-
plaints.
The period of guarantee begins on the date of transfer of risks, in the case of special systems and software on
the date of commissioning, at the latest 30 days after the transfer of risks. In the event of justified notice of
complaint, BARCO can repair the fault or provide a replacement at its own discretion within an appropriate pe-
riod. If this measure proves to be impossible or unsuccessful, the purchaser can demand a reduction in the pur-
chase price or cancellation of the contract (redhibition). All other claims, in particular those relating to compensa-
tion for direct or indirect damage, and also damage attributed to the operation of software as well as to other
services provided by BARCO, being a component of the system or independent services, will be deemed invalid
provided the damage is not proven to be attributed to the absence of properties guaranteed in writing or due to
the intent or gross negligence on the part of BARCO.
If the purchaser or a third party carries out modifications or repairs on good delivered by BARCO, or if the goods
are handled incorrectly, in particular if the systems are commissioned or operated incorrectly or if, after the
transfer of risks, the goods are subject to influences not agreed upon in the contract, all guarantee claims of the
purchaser will be rendered invalid. Not included in the guarantee coverage are system failures which are attrib-
uted to programs or special electronic circuitry provided by the purchaser, e. g. interfaces. Normal wear as well
as normal maintenance are not subject to the guarantee provided by BARCO either.
The environmental conditions as well as the servicing and maintenance regulations specified in this manual must
be complied with by the customer.
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Barco – OL Series – R59115900 – service manual – Revision 00 – October-2010 iii
Revision sheet
To:
• BARCO Control Rooms GmbH
An der Rossweid 5, D-76229 Karlsruhe
Phone: +49-721-6201-0, Fax: +49-721-6201-298
E-mail: docu.de.bcd@barco.com, Web: www.barcocontrolrooms.com
From:
Date:
Please correct the following points in this documentation (R59115900):
page wrong correct
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Barco – OL Series – R59115900 – service manual – Revision 00 – October-2010 iv
Contents
1 Introduction........................................................................................................................................... 7
1.1 Styles and Symbols ........................................................................................................................................ 8
1.2 Safety Instructions .......................................................................................................................................... 9

1.2.1 Standards ............................................................................................................................................... 9
1.2.2 Precautions .......................................................................................................................................... 10
1.2.3 Unpacking of Devices .......................................................................................................................... 12
1.2.4 General installation instructions ......................................................................................................... 12
1.2.5 Servicing............................................................................................................................................... 13
1.2.6 Cleaning ............................................................................................................................................... 13
1.2.7 Re-Packing ........................................................................................................................................... 13
1.2.8 Environmental information: disposal information ............................................................................. 13
2 Best Practices ...................................................................................................................................... 14

2.1 How to change a MAC Address and/or an IP address of a projection system.......................................... 14
2.1.1 Requirements:...................................................................................................................................... 14
2.1.2 Where to edit an IP address / MAC address ...................................................................................... 15
2.1.3 How to access the BCMC web interface ............................................................................................. 15
2.1.4 How to enter the IP address / MAC address in the permanent IP address table?........................... 15
2.1.5 How to restart the DCHP server .......................................................................................................... 16
2.1.6 How to reboot the projection system................................................................................................. 17
2.1.7 How to restart BCM service................................................................................................................. 17
2.1.8 How to delete a MAC address / IP address from the DHCP permanent table ................................. 18
3 Rear access systems ........................................................................................................................... 19

3.1 General.......................................................................................................................................................... 19
3.2 Replacement of the Front End Box.............................................................................................................. 21

3.2.1 Introduce the new front end box to BCM........................................................................................... 23
3.3 Replacement of the projection engine........................................................................................................ 25
3.3.1 Mechanical replacement. .................................................................................................................... 25
3.3.2 Geometry adjustment ......................................................................................................................... 30
3.3.3 Color adjustment ................................................................................................................................. 31
3.4 Replacement of the cooling unit ................................................................................................................. 32
3.5 Replacement of the LED chain ..................................................................................................................... 37
4 Upgrade of Formatter Flash File ......................................................................................................... 40
5 Front access system ............................................................................................................................ 43

5.1 General.......................................................................................................................................................... 43
5.2 Replacement of the cooling unit ................................................................................................................. 46
5.3 Replacement of the front end box .............................................................................................................. 49
5.4 Replacement of the projection engine........................................................................................................ 50
5.5 Replacement of the LED chain ..................................................................................................................... 54
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Barco – OL Series – R59115900 – service manual – Revision 00 – October-2010 v
5.6 Final steps ..................................................................................................................................................... 55
6 Address................................................................................................................................................ 56
6.1 Hot Line......................................................................................................................................................... 56
7 Safety datasheet of cooling liquid ..................................................................................................... 57
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Barco – OL Series – R59115900 – service manual – Revision 00 – October-2010 vi
1. Introduction
1 Introduction
This chapter explains the structure of the manual itself and the used typographic styles and symbols. Safety in-
formation is provided concerning the operation of devices from Barco
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Barco – OL Series – R59115900 – service manual – Revision 00 – October-2010 7
1. Introduction
1.1 Styles and Symbols

The typographic styles and the symbols used in this document have the following meaning:
Bold Labels, menus and buttons are printed in Bold font.

Condensed Links to both other chapters of this manual and to sites in the Internet are printed
condensed. In the on-line version of this manual all hyperlinks appear teal.
Courier Names of files and parts from programs are printed in the Courier font.
Courier bold Inputs you are supposed to do from the keyboard are printed in Courier bold font.
If you do not heed instructions indicated by this symbol there is a risk of damage to the
equipment!
If you do not heed instructions indicated by this symbol there is a risk of electrical shock and
danger to personal health!
If you do not heed instructions indicated by this symbol there is a risk of damage to parts,
which are sensitive towared electrostatic charge!
If you do not heed instructions indicated by this symbol there is a risk to get harmed by sharp
objects!
If you do not heed instructions indicated by this symbol there is a risk that parts may explode!
If you do not heed instructions indicated by this symbol there is a risk that hot parts impact
persons or objects!
The sheet icon indicates additional notes.
Next to this icon you find further information.
This arrow marks tips.
Next to this icon you find important notes.
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1. Introduction
1.2 Safety Instructions

This section describes safety precautions, which must be observed when installing and operating a product from
Barco.
1.2.1 Standards
Safety Regulations
Projection systems of the OL-series are built in accordance with the requirements of the international safety stan-
dards EN 60950-1 Ed.2 (2006), IEC 60950-1, UL 60950-1 and CAN/CSA-C22.2 No. 60950-1, which are the safety
standards of information technology equipment including electrical business equipment.
These safety standards impose important requirements on the use of safety critical components, materials and
isolation, in order to protect the user or operator against the risk of electric shock and energy hazard, and having
access to live parts.
Safety standards also impose requirements to the internal and external temperature variations, radiation levels,
mechanical stability and strength, enclosure construction and protection against risk of fire.
Simulated single fault condition testing ensures the safety of the equipment to the user even when the equip-
ment's normal operation fails.
Electromagnetic Interference
Devices of the OL-Series comply with the following EMC standards:
Electromagnetic compatibility - EN 55022 Ed. 3 (2006)
emission: EN 61000-3-2 (2006)
EN 61000-3-3 (1995) + A1 (2001) + A2 (2005)
Electromagnetic compatibility - EN 55024 Ed. 1 (1998) + A1 (2001) + A2 (2003)

immunity:
EN55022/CISPR22 Class A ITE (Information Technology Equipment)

Devices of the OL-Series are products of class A ITE. ITE means Information Technology Equipment. ITE is subdi-
vided into two categories denoted class B ITE (products intended primarily for use in domestic environment) and
class A ITE (all other ITE which satisfies the class A ITE limits but not the class B ITE limits).
This is a class A product. In a domestic environment this product may cause radio interfer-
ence in which case the user may be required to take adequate measures.
FCC Compliance statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to correct the interference at his own expense.
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1. Introduction
1.2.2 Precautions
For your own protection, observe the following safety precautions when installing and
operating your device:
• Before operating the units please read this manual thoroughly and retain it for future reference!
• Observe all warnings and instructions printed on the devices!
• Do not tilt OL video walls!
• OL video walls need to be installed on a flat floor and fixed to the floor, cf. installation manual.
• Depending on the height of the video wall also wall fixation is required, cf. installation manual.
• OL video walls don't require maintenance work or servicing. In case a projector is broken, call a service tech-
nician! Servicing should never be carried out by unauthorized personnel!
Never open the case of the unit without first disconnecting the power supply cord!
• To prevent fire or electrical shock hazard, do not expose this unit to rain or moisture!
• Do not place warm or heat dissipating sources in the neighborhood of the foam covers of the OL devices.
• This product should be operated from an AC power source!
• Check that the voltage and frequency of your power supply match those printed on the device label with the
rated electrical values!
• If you are not sure of the type of AC power available, consult your dealer or local power company!
• This product is equipped with a 3-wire grounding plug, a plug having a third (grounding) pin. This plug will
only fit into a grounding-type power outlet. This is a safety feature. If you are unable to insert the plug into
the outlet, contact your electrician to replace your obsolete outlet. Do not defeat the purpose of the ground-
ing-type plug!
• This equipment must be grounded (earthed) via the supplied 3 conductor AC power cable. (If the supplied
power cable is not the correct one, consult your dealer.)
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1. Introduction
Mains lead (AC Power cord) with CEE 7 plug:

The wires of the mains lead are colored in accordance with the following code:
yellow + green Earth (Ground)

blue Neutral
brown Line (Live)
Power cord with NEMA 5-15 plug:

The wires of the power cord are colored in accordance with the following code.
Green or Green/Yellow: Earth (Ground)

White or Blue: Neutral
Black or Brown: Line ( Live)
• The cord set must be UL-approved and CSA-certified.

• The minimum specification for the flexible cord is No. 18 AWG Type SVT or SJT, 3-conductor.
• The cord set must have a rated current capacity of at least 10A.
• The attachment plug must be an Earth-grounding type with a NEMA 5-15P (10 A, 125 V) configuration.
Power cord with GB 2099 plug:

The wires of the power cord are colored in accordance with the following code.
yellow + green Earth (Ground)

blue Neutral
brown Line ( Live)
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1. Introduction
• Do not allow anything to rest on the power cord. Do not locate this product where people will walk on the
cord. To disconnect the cord, pull it out by the plug. Never pull the cord itself.
• If an extension cord is used with this product, make sure that the total of the ampere ratings on the products
plugged into the extension cord does not exceed the extension cord ampere rating.
• Never push objects of any kind into this product through cabinet slots as they may touch dangerous voltage
points or short out parts that could result in a risk of fire or electrical shock.
• Never spill liquid of any kind on the product. Should any liquid or solid object fall into the cabinet, unplug the
set and have it checked by qualified service personnel before resuming operations.
• Lightning - For extra protection for this video product during a lightning storm or when it is lift unattended
and unused for a long period of time, unplug it from the wall outlet. This will prevent damage to the unit
due to lightning and AC power-line surges.
This product features a cooling unit with a cooling liquid.

When the cooling unit leaks switch off the projector and contact a service technician.
In the unlikely event that you get in contact with the cooling liquid immediately remove
soiled or soaked clothing.
After inhalation: In the event of symptoms seek medical advice.
After contact with skin: wash off immediately with plenty of water
After contact with eyes: rinse thoroughly with plenty of water and seek medical advice
After ingestion: Summon a doctor immediately.
Please consult the safety datasheet, cf. Safety datasheet of cooling liquid
1.2.3 Unpacking of Devices

Note advises on the packaging for unpacking!
1.2.4 General installation instructions

• Devices of the OL-series must be installed on a flat floor and may not be tilted.
• OL-video walls need to be fixed to floor!
• Depending on the number of rows, OL-video walls need to be fixed to the wall!
About fixation to the floor and to the wall, consult the installation manual!
• Never place warm dissipating devices or heat sources in the neighborhood of the foam covers of the OL
systems.
• Do not use this unit near water.
Make sure that the main switches are accessible and not blocked by e.g. a cladding.
The DIN Rail may not be mounted with the openings looking to the foam or to the bottom.
• Use only the power cord supplied with your unit. While appearing to be similar, other power cords have not
been safety tested at the factory and may not be used to power the unit. For a replacement power cord, con-
tact your dealer.
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1. Introduction
• Slots and openings in the cabinet and the sides are provided for ventilation; to ensure reliable operation of
the unit and to protect it from overheating, these openings must not be blocked or covered. The openings
should never be blocked by placing the product on a bed, sofa, rug, or other similar surface. This product
should never be placed near or over a radiator or heat register. This unit should not be placed in a built-in in-
stallation or enclosure unless proper ventilation is provided.
• The maximum recommended ambient temperature for this equipment is 40 C.
• When using the unit in a multi-unit rack assembly or closed assembly the ambient temperature inside the
assembly may not exceed the maximum rated ambient temperature.
• When installed in a rack, the installation should be such that the amount of air flow required for safe opera-
tion of the equipment is not compromised. The mounting of the equipment should be such that no hazardous
condition is achieved due to uneven mechanical loading.
1.2.5 Servicing
Barco's OL Series does not require servicing or regular maintenance work. In case a projector fails, call a service
technician.
1.2.6 Cleaning
Unplug this product from the wall outlet before cleaning. Do not use liquid cleaners or aerosol cleaners.
1.2.7 Re-Packing
Keep the original shipping carton and packing material; they will come in handy if you ever have to ship your
unit. For maximum protection, repack your set as it was originally packed at the factory.
1.2.8 Environmental information: disposal information

This equipment has required the extraction and use of natural resources for its production. It
may contain hazardous substances for health and environment.
In order to avoid the dissemination of those substances in the environment and to diminish
the pressure on natural resources, we encourage you to use the appropriate take-back sys-
tems.
Those systems will reuse or recycle most of the materials of your end-of-life equipment in a
sound way.
The crossed-out wheeled bin symbol invites you to use those systems.
If you need more information on the collection, reuse and recycling system, please contact
your local or regional waste administrator.
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2. Best Practices
2 Best Practices
All service interventions are restricted to certified people!
Certification requires a training!
Projection modules of the OL series are highly sophisticated system. The functional components comprise the
front end box, the projection engine, the LED chain, and the cooling unit.
In case of mal function these components can be replaced in the field.
Any repair work needs to be done in factory!
Do not open the system unless the system

has been switched to idle (via the Barco Wall Control Manager or via the web interface)
and disconnected from the mains (switched off by the main switch).
(Switching to idle prior to switching off ensures that all data is saved first and avoids data
loss.)
Projection systems of the OL series are addressed via their IP address. The IP address is linked to the MAC address
of the network interface of the front end box. Connecting a projection system to the BCMC-101 for the first time
assigns an IP address of the short term IP address range.
Any manipulation of this initial pair MAC address – IP address (for example assigning an IP address of the perma-
nent IP address range or changing a MAC address after replacing a front end box and so on) requires some steps
to fix the new pair MAC address – IP address.
2.1 How to change a MAC Address and/or an IP address of a projection system
2.1.1 Requirements:
The PC/Laptop is connected to the WALL interface of BCMC.
The projection system is connected to the WALL interface of BCMC
A change in the the MAC address and/or the IP address of a projection system (in general
a change in any of the network settings) requires a reboot of the projection system as
well as a restart of the DHCP server (of the BCMC) and a restart of the BCM service.
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2. Best Practices
Reboot of the projection system needs to be done using the web page of the projection
system.
2.1.2 Where to edit an IP address / MAC address

IP address / MAC address can be edited on the BCMC web interface, page Wall DHCP, section DHCP Permanent IP
address table.
2.1.3 How to access the BCMC web interface

Connect your PC/Laptop to the WALL interface of BCMC.
Launch internet explorer.
In the address bar, enter the URL http://172.29.1.1.
2.1.4 How to enter the IP address / MAC address in the permanent IP address table?
Any device connected to the WALL interface of BCMC gets an IP address by the DHCP server and is listed in the
DCHP short term IP table.
Unless the change of MAC address / IP address has been completed it is exactly this short
term IP address the projection systems is listening to.
On your PC/Laptop, launch a web browser. In its address bar, enter the IP address of the
projection module: the web interface will be opened.
If you neither connect to the projection system nor note the IP address you might later not
be able to reboot the projection system.
In case a device does not show up in the short term IP table check if its MAC address is
already visible in the DHCP permanent table and use the related IP address (the front end
box might have already been connected to the BCMC).
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2. Best Practices
Now switch back to the BCMC web inter face, Wall DCHP, DCHP Permanent IP table.
Select the device in the short term IP table and click on Permanent: This will list the device in the permanent IP
address table with an IP address of the permanent address range.
The command Permanent does not remove the entry from the web page, i.e. the MAC address of the device will
show up twice, once in the short term IP table and in the DHCP Permanent IP table. (After some time, the entry
will disappear automatically, alternatively select the entry and click Remove).
In the DCHP Permanent table you can edit the MAC address and the last octet of the IP address. This is visualized
by a gray background.
In case a front end box is physically replaced and the entry of the previous front end box is still listed in the DHCP
Permanent table you might want to overwrite the MAC address of the previous device with the MAC address of
the new device: This allows later addressing the projection system with the well-known IP address. Alternatively
delete the entry of the previous MAC address from the DHCP permanent table (tick the entry and click Delete)
and modify the IP address of the new device.
The changes of the web page are are only "cosmetic" unless completed by
A restart of the DCHP server
A restart of the projection system
A restart of the BCMC service
2.1.5 How to restart the DCHP server

Select the entry and click Apply – this writes the new pair MAC address / IP address into the DCHP server table.
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2. Best Practices
2.1.6 How to reboot the projection system

Switch to the web interface of the projection system, log in as admin.
Navigate to Projector and click reboot – This introduces the new IP address to the projection system (after reboot
you need to use the new IP address to connect to the projection system).
2.1.7 How to restart BCM service

On the BCMC web interface, navigate to Admin.
Click on Tasks-BCM Service -restart – now the new address gets visible in BCM.
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2. Best Practices
2.1.8 How to delete a MAC address / IP address from the DHCP permanent table
Select the desired entry and click delete: this will remove the entry from the web page.
Click on Apply to restart the DHCP server.
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3. Rear access systems
3 Rear access systems
3.1 General
Do not open the rear cover unless the system

loss.)
The rear cover is fixed by two screws.

To remove the rear cover,
• Loosen the screws
• Pull the rear cover towards you and remove it.
After removing of the rear cover, the functional components inside the structure get accessible. On the right
there are the cooling unit and the front end box, on the left there is the LED chain, in the middle the projection
engine.
With display walls, "left" and "right" are always used as seen from front!
To attach the rear cover, proceed in reverse order.
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The following chapters explain how to replace the cooling unit, the front end box, the projection engine and the
LED chain.
Assumption is made that you are sure that the replacement of a component is required.
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3.2 Replacement of the Front End Box
Before proceeding with the instructions below, make sure that the system has been
disconnected from the mains, cf. Best Practices!
The front end box has interfaces for external cabling (on the right) and internal cabling (on the left).
From the right side of the front end box, disconnect

• Power Cable
• All DVI cables
• LAN cable
From the left side of the front end box, disconnect

• Cooling unit cable
• Image data cable
• Control data cable
• Led unit cable
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The front end box is fixed by 4 screws to a bracket mounted onto the rear horizontal profile. The rear screws are
easy accessible, for the front screws a very long magnetic bit holder comes in conveniently.
• Remove the screws.
• Rotate the bottom side of the Front End Box towards you as shown on the picture.
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• Lift the front end box up and pull it towards you
• To install a new front end box, proceed in the reverse order.
Make sure to connect all cables!

Take care not to hurt or bend the fins of the radiator when installing the front end box!!
Take care that you don't ground the radiator by a closing connection between the radiator
and the front end box.
• Close and fix the cover.
Power up the projection system.
3.2.1 Introduce the new front end box to BCM
The new front end box has a MAC address the BCMC-101 DHCP server automatically assigns an IP address to. You
might want to edit this correlation (please refer also to How to change a MAC Address and/or an IP address of a
projection system):
• Launch Barco Wall Control Manager client.

• Log in as admin
• In the service view, right-click on the node of BCMC.
• From the context menu, select show web interface.
The web interface of BCMC-101 opens.
Click on Wall DHCP
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The new front end box will be listed in the short term IP table with its MAC address and a random IP address of
the short term range.
In case the old projection system is still listed in the permanent IP table, just edit the "old" MAC address to be-
come the new one.
Select the entry in the short term IP table and click Remove.
In the permanent IP table, select the modified entry and click Apply: This will assign the "old" permanent IP
address to the new MAC address.
Alternatively select the entry of the replaced front end box in the permanent IP table and click delete.
Subsequently click Add and fill in the new MAC address.
Edit the automatically assigned IP address to match the IP address of the removed projection system.
Select the entry and click Apply.
Clicking Apply restarts the DHCP server.

In addition the BCM service needs to be restartet (on the page Admin of the BCMC web
interface.
To "link" the MAC address with the IP address the projection systems need to reboot.
If applicable, navigate to Devices. Select the new projection system and configure it wrt Input, Input selection
mode, timing, scaling, and grouping.
In the BCM client, select the video wall and trigger a Sense6 color adjustment cycle to link the new front end box
(MAC address) with the color settings of the projection engine.
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3.3 Replacement of the projection engine
Replacement of the projection engine comprises the mechanical replacement of the component, the geometry
adjustment of the system with the new projection engine, and the color adjustment of the modified projection
module to the target of the video wall
3.3.1 Mechanical replacement.
Make sure that you have the correct spare part for the system! The projection engines are
calibrated for 50" and 70", respectively. In addition the lens for the 50" systems features a
metal distance ring. (Spare part number R9843700 for 50" systems, R9843701 for 70"
systems).
The spare projection engine also comprises the LED chain.
The projection engine is controlled by and connected to the front end box. Next to cable connections to the front
end box there are also connections of the cooling tubes to the cooling unit.
Before de-mounting the projection engine all cables and tubes need to be disconnected from the projection en-
gine.
• From the projection engine, disconnect the DVI cable (image data) and the serial cable (control data) coming
from the front end box.
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• From the projection engine, disconnect the red-black LED driver cable coming from the font end box.
• Disconnect the two cooling tubes like this:

Gently press on the white button
Pull the two connection parts gently out of each other
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In case any liquid is spilled remove it according the instructions of the safety datasheet, cf.
Safety datasheet of cooling liquid.
The projection engine is mounted to the left and right interface plate (slider) on the horizontal profile. The inter-
face plate of the horizontal profile features two pins which interlock with the interface plate of the projection
engine.
Locking is done via the screw. Fixing the screw moves the projection engine up. Opening the screw moves the
projection engine down and releases the pin connection.
• Use an allen key to open the screws.
Do not apply brute forces! Only open the screws. They are not to be removed!
Otherwise you will destroy the retaining washer of the slider lock screw.
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Take care not to scratch the lens!

Always turn both screws simultaneously ( alternatively one by one in small steps, e.g. 2
turns in one go).
• While turning the screws, watch the pins!

• When the pins are no longer locked into the interface of projection engine (= the screws are their end) fetch
the projection engine. Slide it towards you. Carefully take it out!
• Put the projection engine on a flat surface. Do not place it on the lens!
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• Make sure that you have the correct spare part!

• Take the new projection engine. Do not remove the lens cap!
• Make sure that the fixation screws are open!
• Put it onto the left and right slider of the horizontal profile and push it back as far as it goes.
Only when it has reached its end position on the sliders (x, z direction), fix the screws for the pin connection.
• Fix the two screws.
Fix the screws simultaneously. Alternatively make two turns of the left screw, then of the
right screw, and so on, until the screws are fixed.
Watch the pin connection!
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• When the projection engine is installed, remove the lens cap.
Do not touch the lens!
• Re-connect the tubes of the cooling cycles.

• Plug in the cables! (DVI cable, serial cable, red-black LED driver cable).
• Care for a correct layout of the cabling!
Cabling 50" systems cabling 70" systems
3.3.2 Geometry adjustment

• Power up the projector.
• Apply a test pattern
• Check the key stone alignment.
With new systems key stone adjustment has been done and fixed (setting of the top left/right mirror adjustment
screw, rear mirror adjustment screw, nominal position n1 = 11mm, n2 = 24mm (50" systems), n1=18mm,
n2=19.4mm (70" systems).
During installation advice has been given to open the counter nuts of the top left/right mirror adjustment screw.
Thus key stone adjustment has been enabled.
• While adjusting the top left/right mirror adjustment screws, watch the grid on the screen!
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Fine tuning of key stone adjustment is done via the mirror surface rectifiers on the mirror borders. In total there
are 16.
• Use a hexagon key and carefully turn the screw(s) (M4x16) of the respective rectifier(s).
Shift, zoom, rotate and focus are adjusted via the Barco Wall Control Manager client.

• Log in as admin
• If required, open the video wall in the editor area.
• Right-click on the respective cell in the grid, representing the repaired system. From the context menu, se-
lect Geometry adjustment.
• Perform the geometry adjustment until the grid is perfect.
3.3.3 Color adjustment

• Log in as admin
• Right-click on the respective cell in the grid, representing the repaired system. From the context menu, se-
lect Operation mode.
• In the task panel, set the operation mode from manual to Sense6.
• Click Apply.
• Select the entire wall.
• In the task panel, click on Apply&Trigger to initiate a color adjustment.
• When the adjustment procedure has been done, check the result of the color adjustment.
• If required, select the respective projection module.
• In the task panel, enable Manual correction.
• Perform a manual fine tuning of the color adjustment.
Please refer also the user manual of Barco Wall Control Manager for OL Series.
When the mechanical replacement, geometry adjustment and color adjustment has been done,
________________________________________________________________________________
3.4 Replacement of the cooling unit
• De-mount the front end box as explained in Replacement of the Front End Box.

• Remove the two screws
________________________________________________________________________________
• Open the partition wall to get access to the cooling unit.

The partition wall is the plastic part in the projection module and can be opened by turning the knob located at
the left.
If the partition wall is closed, the holes of the knob are looking horizontal.
If the partition wall is opened, the holes of the knob are looking vertical.
• Turn the knob until the holes are vertical to open the partition wall.
• Push the partition wall up (there is a hinge which snaps in and keeps the partition wall up)
• Lift the cooling unit and slide it back.
________________________________________________________________________________
• Rotate the cooling unit and take it out.
The component you took out is the cooling unit mounted to the bracket of the front end
box.
Remove this bracket from the cooling unit (it is fixed by two screws M4x8 (B360868).
Take care not to loose the screws!
Make sure that you have the correct spare part (R9843720 for 50" systems, R9843730 for
70" systems. The difference is in the length of the tubes).
• Control for any liquid outside the cooling unit while unpacking
________________________________________________________________________________
• Check if fins of cooling radiator are bent, max 3 that come in contact are allowed.
• Check if liquid tubes are correctly mounted to the nozzle of the radiator.
• Check if liquid tubes do not show any damage.
• Check that liquid reservoir is sufficiently filled (membrane in upper third of available reservoir space).
• Take the new cooling unit and remove the protective cover from the radiator
Mount the bracket to the cooling unit using two screws M4x8. It is this assembly which is
to be placed back into the projection module.
• Place the new cooling unit into the projection module.

• Fix it using the screw M6x50 (right) and M6x20 (left) (seen from front)
• Check that there is no electrical contact between the outlets of the cooling unit and the module by using a
Ohmmeter. Use the unprotected copper parts and the holder of the cooling unit (Ω = ∞).
________________________________________________________________________________
• Lift the partition wall up to release the hinges.

• Turn the partition wall down.
The hinge moves in the small gap between the cooling unit and the projection engine.
This space may be also covered by cables. Make sure to put the cables aside to prevent the
partition wall to cut the cables.
• Lock the partition wall (the holes of the knob need to be horizontal).
• Re-install the front end box as explained in Replacement of the Front End Box
• Connect the cooling tubes.
________________________________________________________________________________
3.5 Replacement of the LED chain
• Carefully remove the connectors of the red, green, and blue cables from the LED (do not pull on the wires!).
• Open the clips and remove the Leeds.
• Remove the plastic insulation part (plastic inter poser) of each LED of the "old" LED chain.
________________________________________________________________________________
• Take the new LED chain.

• Apply the plastic inter poser to each LED of the new LED chain.
This plastic part is the insulator interface and ensures that the LED is insulated against the
metal housing! If the plastic inte poser are not attached correctly the metal housing will
be under voltage!
In addition the plastic interposer keeps the LED in the correct position.
The following picture shows the sequence of the LED.
The light entrances of the projection module are also marked with R for red, G for green and B for blue. Connect
the LED chain with correct color matching to the entrances.
• Check that position of the 4 guiding pins of an LED is correct then fix the clip
• Clip both sides of the metal spring to the hooks in the clip safely on for proper fit of each LED.
________________________________________________________________________________
Pay attention not to touch the LED and the lens on the light entrance at any time of
assembly.
• Close the cover and fix it.

• Log in as admin
• Select the entire video wall.
• In the task panel, click on Apply&Trigger to initiate a color adjustment.
• When the adjustment procedure has been done, check the result of the color adjustment.
• If required, select the respective projection module in the grid.
• In the task panel, enable Manual correction.
• Perform a manual fine tuning of the color adjustment.
Please refer also to the user manual of Barco Wall Control Manager for OL Series.
• Log in as expert to the web interface of the projection engine.

• Navigate to Runtimes.
• Reset the LED runtime.
________________________________________________________________________________
4. Upgrade of Formatter Flash File
4 Upgrade of Formatter Flash File
All service interventions are restricted to certified people!

Certification requires a training!
Make sure that you have a valid formatter flash file.
Make sure you have the R&D tool "Pico tool" installed on your laptop. If required, contact Barco Customer Support
to get the setup.exe.
To upgrade the formatter flash file, you need to connect your laptop to the projection system.
In case the projection system is part of an OL video wall, connect the laptop to the WALL interface of BCMC.
Launch BCM client.
Click on the settings button of the properties view (possible even in read-only mode).
In the section Select Property for Projector View select IP.
The IP addresses are displayed in the grid.
Note down the IP address of the projector(s) you want to upgrade the formatter flash file.
Launch the R&D tool "Pico Tool".
________________________________________________________________________________
Enter the IP address of the projection engine into to respective field and click Detect Projector to establish a
connection to the projection engine.
The status bar will indicate Success: Projector found and show a green connection icon.
Click on Browse.
The standard Windows dialog for opening a file pops up. Navigate to and select the new formatter flash file.
________________________________________________________________________________
Before loading the new formatter flash file it is recommended to click on Check Formatter flash to get the in-
formation about the currently active flash file.
If it is really outdated, click on Update Fmtr flash to load the new file into the projection engine. In case the
actual version of the formatter flash file is the current one, no update is required.
When the new formatter flash file has been loaded to the projection engine the projection system will reboot.
Click Exit to quit the Pico Tool application.
________________________________________________________________________________
5. Front access system
5 Front access system

This section describes exchanging the components from front. In case the front access system provides a suffi-
cient service area on the rear it is highly recommended to replace the components from rear!
5.1 General
Do not open the screen unless the system
loss.)
To open the screens of front access systems, the tool R867957 is required.
Check the quality of the tool! It needs to have round borders and needs to be perfectly deburred! Make sure that
it is not bended!
Use it carefully! The tool must not come in touch with the screen borders! Otherwise you risk peeling off the front
foil of the screen!
Insert this tool into the horizontal gap of adjacent screens and search for the correct slot, see picture. The right
slot of a pair of slots always refers to the screen below, the left slot for the screen above.
________________________________________________________________________________
Use the tool R867957 to open the screen of the respective system. Insert it into the horizontal gap and find the
corresponding slots.
Make sure not to lever off the tool! Up or down movements will damage the screen
Press against the screen (to keep it closed) and open the respective sliders.
Subsequently use the tool and hook it to the screen.

Pull the screen open.
Wear a hard hat when "crawling" into the open system! The screen module has very sharp
edges!
Turn the knob to unlock the partition wall.
________________________________________________________________________________
If the partition wall is closed, the holes of the knob are looking horizontal.
If the partition wall is opened, the holes of the knob are looking vertical.
Open the partition wall. Make sure that the hinges click into place.
________________________________________________________________________________
5.2 Replacement of the cooling unit
• Open the system as explained in 5.1 General

The cooling unit is fixed with two screws B360868 (SCR $7985/M 4x8 STZN).
Take care not to scratch the mirror!!
When pulling out the cooling unit make sure not to cut or dammage the cables guided in
the small gap between the cooling unit and the hing of the partition wall!
________________________________________________________________________________
It might also be recommended to carefully push back the silicon rubber sealing of the fan and to push the cooling
unit to the right.
• Lift out the cooling unit.
If required, remove the silicon rubber sealing of the fan.

• Take the new cooling unit and remove the protective cover from the radiator.
________________________________________________________________________________
Make sure that you have the correct spare part (R9843720 for 50" systems, R9843730 for
70" systems. The difference is in the length of the tubes).
• Control for any liquid outside the cooling unit while unpacking
• Check if fins of cooling radiator are bent, max 3 that come in contact are allowed.
• Check if liquid tubes are correctly mounted to the nozzle of the radiator.
• Check if liquid tubes do not show any damage.
• Check that liquid reservoir is sufficiently filled (membrane in upper third of available reservoir space).
(In case the silicon rubber sealing of the fan is still in place remove the sealing from the new cooling unit. Else
place the new sealing into the display module).
• Install the new cooling unit in reverse order.

• Connect the cooling tubes.
• Check that there is no electrical contact between the outlets of the cooling unit and the module by using a
Ohmmeter. Use the unprotected copper parts and the holder of the cooling unit (Ω = ∞).
• Subsequently complete the intervention, cf. 5.6 Final steps
________________________________________________________________________________
5.3 Replacement of the front end box
Open the system as explained in 5.1 General
The front end box has interfaces for external cabling (on the right) and internal cabling (on the left).
From the right side of the front end box, disconnect

• Power Cable
• All DVI cables
• LAN cable
From the left side of the front end box, disconnect
• Cooling unit cable
• Image data cable
• Control data cable
• Led unit cable
Replacing the front end box starts with replacing the cooling unit, 5.2. Replacement of the cooling unit
The front end box is de-mounted together with the front end box bracket.
• Remove the two screws B362666 (SCR D7985TXM 6x7 STBK). The bracket will still hang on the horizontal
profile.
________________________________________________________________________________
• Remove the front end box.
To ins tall the new front end box, proceed in reverse order.
The front end box installation bracket features a small lug at the rear. Feed this lug into the corresponding hole
on the horizontal bracket to define the correct position of the front end box.
• Connect all cables to the front end box and re-install the cooling unit.
• Subsequently complete the intervention, cf. 5.6 Final steps
• Take the system in operation again, cf. 3.2.1 Introduce the new front end box to BCM
5.4 Replacement of the projection engine
Make sure that you have the correct spare part for the system! The projection engines are
calibrated for 50" and 70", respectively. In addition the lens for the 50" systems features a
metal distance ring. (Spare part number R9843700 for 50" systems, R9843701 for 70"
systems).
The spare projection engine also comprises the LED chain.
Open the system as explained in 5.1 General
________________________________________________________________________________
• Apply the lens cover.

The projection engine is controlled by and connected to the front end box. Next to cable connections to the front
end box there are also connections of the cooling tubes to the cooling unit.
• Disconnect all cable connections between the front end box and the projection engine from the front end
box. Do not disconnect them from the projection engine!
• Pull the cables outside.

________________________________________________________________________________
The projection engine is de-installed by de-mounting the engine interface brackets from the horizontal profile.
The left and the right bracket are each fixed with two "diagonal arranged" screws B363372 (SCR $7500 M6x29
STZN), one fixed to the upper groove of the profile, one to the lower groove.
For your convenience you might place them into the connection corner.
Besides the connection via the screws, the interface bracket hangs on two pins on the horizontal profile.
________________________________________________________________________________
• Fetch the projection engine and tilt it to remove it from the pins.
The projection engine is still hanging onto the profile due to the bent design of the interface brackets.
Subsequently shift the projection engine to the right until both interface brackets are positioned at the cut outs of
the partition wall.
• Lift the projection engine out and put it on a flat surface as shown on the picture. Do not place it on the lens!
• To install the new projection engine proceed in reverse order.

• When installed, remove the lens cover.
________________________________________________________________________________
• Complete the intervention, cf. 5.6 Final steps

• Subsequently perform the geometry adjustment, cf. 3.3.2 Geometry adjustment
5.5 Replacement of the LED chain

When repair is done from front replacing the LED chain requires demounting the projection engine, cf. 5.3
Replacement of the projection engine.
Carefully place the projection unit on a table and replace the LED chain as described in 3.5 Replacement of the LED
chain
________________________________________________________________________________
5.6 Final steps
• Lift the partition wall up to release the hinges.

• Turn the partition wall down.
The hinge moves in the small gap between the cooling unit and the projection engine.
This space may be also covered by cables. Make sure to put the cables aside to prevent the
partition wall to cut the cables.
• Lock the partition wall (the holes of the knob need to be horizontal).
Press the red area on the right gas spring backward and close the screen.
To lock the sliders, use the tool R867957.

Use it carefully! The tool must not come in touch with the screen borders! Otherwise you risk peeling off the front
foil of the screen!
Insert this tool into the horizontal gap of adjacent screens and search for the correct slot, see picture. The right
slot of a pair of slots always refers to the screen below, the left slot for the screen above.
Insert the tool into the respective slot and lock the slider.
Make sure not to lever off the tool! Up or down movements will damage the screen!
• Close the screen

• Lock the screen sliders.
________________________________________________________________________________
6. Address
6 Address
6.1 Hot Line
Feel free to contact us if you have any further questions!

• BARCO N.V. - Europe
President Kennedypark 35, B-8500 Kortrijk
Phone: +32-56-368-282,
E-mail: support.controlrooms@barco.com, Web: www.barcocontrolrooms.com
________________________________________________________________________________
7. Safety datasheet of cooling liquid
7 Safety datasheet of cooling liquid
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________

R59115900 00 Service

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R59115900 00 Service

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Copyright © 2010by Barco

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Please correct the following points in this documentation (R59115900):

page wrong correct

1.2 Safety Instructions .......................................................................................................................................... 9

2 Best Practices ...................................................................................................................................... 14

3 Rear access systems ........................................................................................................................... 19

3.2 Replacement of the Front End Box.............................................................................................................. 21

3.5 Replacement of the LED chain ..................................................................................................................... 37

4 Upgrade of Formatter Flash File ......................................................................................................... 40

5 Front access system ............................................................................................................................ 43

5.2 Replacement of the cooling unit ................................................................................................................. 46

5.3 Replacement of the front end box .............................................................................................................. 49

5.4 Replacement of the projection engine........................................................................................................ 50

5.5 Replacement of the LED chain ..................................................................................................................... 54

7 Safety datasheet of cooling liquid ..................................................................................................... 57

1.1 Styles and Symbols

Bold Labels, menus and buttons are printed in Bold font.

The sheet icon indicates additional notes.

Next to this icon you find further information.

This arrow marks tips.

Next to this icon you find important notes.

1.2 Safety Instructions

Electromagnetic compatibility - EN 55024 Ed. 1 (1998) + A1 (2001) + A2 (2003)

EN55022/CISPR22 Class A ITE (Information Technology Equipment)

FCC Compliance statement

Mains lead (AC Power cord) with CEE 7 plug:

yellow + green Earth (Ground)

Power cord with NEMA 5-15 plug:

Green or Green/Yellow: Earth (Ground)

• The cord set must be UL-approved and CSA-certified.

Power cord with GB 2099 plug:

yellow + green Earth (Ground)

This product features a cooling unit with a cooling liquid.

1.2.3 Unpacking of Devices

1.2.4 General installation instructions

1.2.8 Environmental information: disposal information

In case of mal function these components can be replaced in the field.

Any repair work needs to be done in factory!

Do not open the system unless the system

2.1 How to change a MAC Address and/or an IP address of a projection system

2.1.2 Where to edit an IP address / MAC address

2.1.3 How to access the BCMC web interface

2.1.5 How to restart the DCHP server

2.1.6 How to reboot the projection system

2.1.7 How to restart BCM service

3 Rear access systems

Do not open the rear cover unless the system

The rear cover is fixed by two screws.

To attach the rear cover, proceed in reverse order.

3.2 Replacement of the Front End Box

From the right side of the front end box, disconnect

From the left side of the front end box, disconnect

• Lift the front end box up and pull it towards you

• To install a new front end box, proceed in the reverse order.

Make sure to connect all cables!

• Close and fix the cover.

Power up the projection system.

3.2.1 Introduce the new front end box to BCM

• Launch Barco Wall Control Manager client.

The web interface of BCMC-101 opens.